Exercise and swim spa

ABSTRACT

One example of this application provides a method for manufacturing an above-ground heated pool used for swimming resistance exercise (exercise and swim spa), with an optional attached hot tub. Additionally, the rotationally-molded swim spa can support the addition of an integrated separate water vessel, used primarily for relaxation, that can maintain a separate water temperature from the swim spa section of the whole system. Other variations of this application have also been discussed.

RELATED APPLICATIONS

This application is a continuation of (related to) the provisional application Ser. No. 61/332,818, filed 10-May-2010, with the same title, inventor(s), and assignee.

BACKGROUND OF THE INVENTION

One embodiment of this invention provides a method for manufacturing an above-ground heated pool used for swimming resistance exercise (exercise and swim spa), with an optional attached hot tub.

Large pools using jets to create a resistance current to swim against have long been known and are widely used. These types of exercise systems have been manufactured as above-ground and in-ground units for a couple of decades. Swim spas or exercise pools of this type have been traditionally manufactured utilizing in-ground concrete construction, or for above-ground versions (which can also be manufactured for in-ground use), with fiberglass shells, vacuum formed acrylic sheet reinforced with ABS, or fiberglass or vacuum-formed polyethylene. The above-ground versions need a separately-manufactured cabinet to support the shell.

Smaller hot tubs manufactured utilizing the rotational molding process have been made for many years, but no one has yet produced a swim spa, for the purposes of swimming against a powerful current of water, designed to provide resistance for endurance training The equipment usually needed to mold a rotationally molded swim spa is known as a rock-n-roll rotational molding machine. Although, a traditional bi-axel, or offset arm on an exceptionally large carousel, swing or clamshell rotational molding machine, is also possible. U.S. Pat. No. 5741453, by Kennedy, filed Nov.-7-1995, teaches a “Method for making rotationally molded SPA”, as an example of the prior art.

The advantages provided by this invention (as one embodiment) include a cost effective method of construction, over traditional methods for manufacturing swim/exercise spas. Additionally, the rotationally-molded swim spa can support the addition of an integrated separate water vessel, used primarily for relaxation, that can maintain a separate water temperature from the swim spa section of the whole system. This separate section can be molded together with the swim spa section, to create one contiguous molded piece, or it can be molded separately and mechanically attached, so that the swim spa can be sold individually, or optionally with the additional hot tub unit.

SUMMARY OF THE INVENTION

One embodiment of this invention provides a method for manufacturing an above-ground heated pool used for swimming resistance exercise (exercise and swim spa), with an optional attached hot tub. Additionally, the rotationally-molded swim spa can support the addition of an integrated separate water vessel, used primarily for relaxation, that can maintain a separate water temperature from the swim spa section of the whole system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an embodiment of this invention: a cross section of the support for a hot tub. The hot tub would rest inside this support.

FIG. 2 shows an embodiment of this invention: a cross section of an exercise or swim spa, with an optional attached hot tub.

FIG. 3 shows an embodiment of this invention: the bottom view of an exercise or swim spa, with an optional attached hot tub.

FIG. 4 shows an embodiment of this invention: an exercise or swim spa, from the top view.

FIG. 5 shows an embodiment of this invention: the 3D view of an exercise or swim spa, with an optional attached hot tub.

FIG. 6 shows an embodiment of this invention: a cross section and a 3D view of a hot tub support cradle platform. The hot tub rests inside.

FIG. 7 shows an embodiment of this invention: the 3D view and cross section of an exercise or swim spa, with an optional attached hot tub.

FIG. 8 shows an embodiment of this invention: the 3D view of a hot tub cradle section.

FIG. 9 shows an embodiment of this invention: the 3D view of a hot tub cradle section, from bottom.

FIG. 10 shows an embodiment of this invention: the 3D view of a hot tub and swim spa cradle attached.

FIG. 11 shows an embodiment of this invention: the 3D view of an exercise or swim spa, with an optional attached hot tub.

FIG. 12 shows an embodiment of this invention: the 3D view of an exercise or swim spa.

FIG. 13 shows an embodiment of this invention: the top view of an exercise or swim spa.

DETAILED EMBODIMENTS OF THE INVENTION

As an individual swim resistance system (as one embodiment), the swim spa can be 8′ to 20′ in length, 3′ to 6′ in height, and 5′ to 9′ in width (as an example). These dimensions provide for a typical area and water volume for swimming and other exercise activities.

The optional segregated hot tub area can be of any size (as one embodiment), to accommodate one or more individuals, however, at a typical, lower range/ dimensions, it can be 4′ to 10′ in length, 29″ to 6′ in height, and 4′ to 9′ in width (as an example).

However, the sizes mentioned here are typical ranges for some embodiments, as examples, and the invention covers any size, big or small, for the method of manufacturing the system/ object (swim and exercise spas).

“Wikipedia.org” (on the Internet) has a very descriptive section about “Rotational molding”, also known as roto-molding (as prior art), as detailed here: It is a molding process for creating many kinds of hollow items. A heated hollow mold is filled with a charge of material. Then, it is slowly rotated (usually around two perpendicular axes), causing the softened material to disperse and stick to the walls of the mold. In order to maintain even thickness throughout the part, the mold continues to rotate at all times 4 during the heating phase (and to avoid deformation during the cooling phase). The system generally comprises molds, an oven, a cooling chamber, and mold spindles.

The rotational molding process is a high-temperature, low-pressure plastic-forming process that uses heat and biaxial rotation (i.e., angular rotation on two axes) to produce hollow, one-piece parts. Here are some of the methods and equipment, from prior art, as described by “Wikipedia.org” (on the Internet):

-   -   Rock and roll machine is a specialized single arm machine. It         rotates or rolls the mold 360 degrees in one direction and at         the same time tips and rocks the mold 45 degrees above or below         horizontal in the other direction.     -   Clamshell machine is a single arm rotational molding machine.         The arm is usually supported by other arms on both ends. The         clamshell machine heats and cools the mold in the same chamber.     -   Vertical or up and over rotational machine, with loading and         unloading area at the front of the machine between the heating         and cooling areas, is energy efficient, due to their compact         heating and cooling chambers.     -   Shuttle or swing arm machine is a single arm turret machine that         moves the mold back and forth between the heating and cooling         chambers.     -   Carousel machine can have up to 6 arms and comes in a wide range         of sizes. The machine comes in two different models, fixed and         independent.

A typical rotational molding process consists of 4 phases, as described by “www.Wikipedia.org” (on the Internet):

-   -   Loading a measured quantity of polymer (usually in powder form)         into the mold.     -   Heating the mold in an oven while it rotates, until all the         polymer has melted and adhered to the mold wall.     -   Cooling the mold, usually by fan, sprayed water or mist.     -   Removal of the part.

A typical material used (as described by “www.Wikipedia.org”) is cross-linked polyethylene (PE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), PVC plastisols, nylons, polypropylene, polyvinyl chloride, and polycarbonate.

In one embodiment, the spa shell, floor, walls, etc, are all molded as one piece.

The swim resistance system (as one embodiment) is made up of one or more motors attached to water pumps, suction fittings, a filtration system, and jets, which interconnect to each other, to provide the directed stream of water used to provide the resistance for the exercise.

The material of the swim spa may comprise one or more of the following: plastic, elastic material, wood, alloy, metal, magnetic material, ferromagnetic material, wool, fabric, clothing, porous material, absorbing, non-absorbing material, mixture, combination, smooth material, coarse material, carved material, molded material, transparent, translucent, opaque material, natural, synthetic material, flexible, rigid material, uniform, non-uniform material, embedded material (embedded with e.g. water pipes or heater wires), hollow material, or reinforced material (e.g. with metal bar, fabric, or mesh).

The shape of the swim spa may be one or more of the following: oval, rectangle, square, straight, curved, circular, multiple cross sections, or single cross section, comprising one or more of the following: multiple jets, single jet, multiple flows, single flow, with flow meter, with holes or grids in the wall to remove or dampen down the waves, recycle mechanism, cleaning mechanism, floating object(s), submerged object(s), walking exercises, with floating tube, with floating jacket, with floating belt, light, underwater light, dancing light monitored by a computer, with music synchronization, multiple lights, gradual changing lights, rainbow lights, lasers, or any combination of the above.

Figures show various embodiments for the current invention, with the current/water flow indicated by arrows in the longitudinal direction of the swim spa, possibly going on either directions (for different embodiments), with diagonal directions, at different angles at 3-dimensional coordinates, changing or fixed, with different speed and pressure, variable or fixed, in terms of time and coordinate, as different embodiments, for different nozzles or openings, fixed or rotating, periodically or irregularly/randomly.

FIG. 1 shows an embodiment of this invention: a cross section of a hot tub, with the following components and features:

-   -   100: SPA section attaches to swim section and is designed to         hold and support a filled hot tub, or for example, an         approximately 0.5-10 m³ range of liquid (e.g., water), or about         0.5-10 tons.     -   140: Hot tub drop-in.     -   110, 111: one or more supports at the bottom of the SPA section.     -   112, 114, 116: sides of the support (110), having a corrugated         shape.     -   136: bottom of the SPA section     -   132, 134: the sides of the SPA section     -   130: Lip at the edge(s) of the SPA section     -   120, 122: inside dimensions of SPA section, e.g., 30 inch high.     -   124: outside height of SPA section, e.g., 55 inch.     -   Hot tub to drop in, e.g., FreeFlow Model Accent, 80″ L×62″ W×32″         H.

FIG. 2 shows an embodiment of this invention: a cross section of an exercise or swim spa, with an optional attached hot tub, with the following components and features:

-   -   266: the inside surface of the swim section.     -   210: one or more supports at the bottom of the SPA section.     -   236: bottom of the SPA section     -   232: the attaching side of the SPA section.

SPA section (200) attaches to swim section (201) at their facing sides (257 and 256, respectively). In one example, the connecting assembly comprises of attachment boards/shims (262, 263), e.g., plywood, that are pressed or attached together via a mechanism such as knots and bolts (264).

Recessed surfaces (260, 261) of swim section and SPA section at their edges, respectively, provide a cavity (252) for insertion and connection (251) by an esthetic piece (250), e.g., a roto-plastic shim. This can also seal the joint. In one embodiment, as shown in 270, the esthetic piece covers (271) the edges (272 and 273) of the SPA and swimming sections. In one embodiment, the edges of SPA and swimming sections (272 and 273) are protruded upwards, to help prevent water getting between the sections.

A platform support (254), e.g., a plywood, is attached (255) or placed under the swim section (201) and SPA section (200). This, for example, can provide leveling and stability to the connecting sections, as well as distributing the weight more evenly.

FIG. 3 shows an embodiment of this invention: the bottom view of an exercise or swim spa, with an optional attached hot tub. SPA section (300) attaches to swim section (301) at their facing sides. In one embodiment, the bottom sides (304 and 305) of SPA section and swim section (respectively) are recessed, with (for example) one or more channels (320, 322, and 324 on SPA section and 321, 323, and 325 on swim section). These recessed channels are designed to be aligned (310), when connecting SPA section and swim section.

One or more connecting boards/rods/shims (e.g., 330, 332, 334) are placed (e.g., 340, 341) in the channels (e.g., molded) (e.g., 320, 321) of SPA section and swim section. In one embodiment, the connecting boards are attached to SPA section and swim section by bolts. In one embodiment, the boards provide support and alignment/leveling for the connection between SPA section and swim section. In one embodiment, 2 or 3 “2×4” boards are connected (e.g., bolted) to the bottom inside molded channels for support.

FIG. 4 shows an embodiment of this invention: an exercise or swim spa, from the top view. In one embodiment, the swim section (401) comprises one or more nozzles or openings (415) to provide water flow (416) (and resistance force against swimming). One embodiment includes one or more (e.g., 410 and 411) suction fittings at the inside walls of the swim section. In one embodiment, the swim section includes one or more seats (402, 403) (e.g., molded). One embodiment includes one or more filters (e.g., 404 and 405).

FIG. 5 shows an embodiment of this invention: the 3D view of an exercise or swim spa, with an optional attached hot tub. It has a swim section, spa connection, and a connection section. It has a lip around the edges (e.g. at the height of 1′-3′) to accommodate the attachment of the wood to the exterior.

FIG. 6 shows an embodiment of this invention: a cross section and a 3D view of a hot tub. The spa section is attached to swim section, and it is designed to hold and support a filled hot tub, or approximately 0.5-10 m³ range of liquid (e.g., water), or about 0.5-10 tons, as an example. The typical values for inside and outside height/depth of the hot tub can be 30″ and 55″, respectively, as an example. The dimensions of the hot tub (e.g. drop-in FreeFlow Model Accent) are 80″ L×62″ W×32″ H, as an example.

FIG. 7 shows an embodiment of this invention: the 3D view and cross section of an exercise or swim spa, with an optional attached hot tub. Two or three 2×4 pieces of wood/lumber can be used, as an example, bolted to the bottom, inside molded channels, for support.

FIG. 8 shows an embodiment of this invention: the 3D view of a hot tub cradle section, with pieces and sections, including the features on them. FIG. 9 shows an embodiment of this invention: the 3D view of a hot tub cradle section, from the bottom.

FIG. 10 shows an embodiment of this invention: the 3D view of a hot tub and swim spa cradle attached, from the bottom, with reinforcement ribs, in parallel, for strengthening the structure. FIG. 11 shows an embodiment of this invention: the 3D view of an exercise or swim spa, with an optional attached hot tub.

FIG. 12 shows an embodiment of this invention: the 3D view of an exercise or swim spa, as swim section, with wood or synthetic wood paneling mechanically attached to the sides, e.g. with glue, screws, bands, chain, pins, nail, or similar devices. FIG. 13 shows an embodiment of this invention: the top view of an exercise or swim spa, similar to the description of FIG. 4.

In one embodiment, we have a swim spa, with one or more of the following features:

-   -   one or more water, air, or liquid jets, openings, orifices, or         nozzles, located inside structure;     -   a drain, for draining water or liquid;     -   one or more pipes, for circulation of water or liquid through         said structure;     -   a pump or compressor, connected to said one or more pipes.     -   one or more supports for structure.     -   one or more valves.     -   one or more faucets.     -   one or more steps or ladders.     -   one or more lights.     -   one or more underwater lights.     -   one or more hot tubs.     -   one or more spa sections.     -   one or more connection sections.     -   one or more pieces of board, lumber, or wood.     -   one or more shims, plywood, or bolted sections.     -   one or more ribs.     -   one or more side panels, walls, tiles, or sections.     -   one or more filters.     -   one or more fittings.     -   one or more water stoppers or caps.     -   one or more flow meters.     -   one or more seats.     -   one or more radios, televisions, or telephone sets.     -   one or more heating elements for heating water.     -   one or more controllers that monitor or adjust temperature,         filter cycles, or speed of jets or current.     -   one or more interfaces or controls for controlling function of         swim spa or hot tub.

Any variations of the teachings above are also meant to be covered and protected by this current application. 

1. A swim spa, said swim spa comprising: a rotationally-molded structure, capable of containing water or liquid; one or more water, air, or liquid jets, openings, orifices, or nozzles, located inside said rotationally-molded structure; a drain, for draining water or liquid from said rotationally-molded structure; one or more pipes, for circulation of water or liquid through said rotationally-molded structure; and a pump or compressor, connected to said one or more pipes.
 2. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more supports for said rotationally-molded structure.
 3. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more valves.
 4. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more faucets.
 5. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more steps or ladders.
 6. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more lights.
 7. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more underwater lights.
 8. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more hot tubs.
 9. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more spa sections.
 10. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more connection sections.
 11. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more pieces of board, lumber, or wood.
 12. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more shims, plywood, or bolted sections.
 13. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more ribs.
 14. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more side panels, walls, tiles, or sections.
 15. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more filters.
 16. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more fittings.
 17. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more water stoppers or caps.
 18. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more flow meters.
 19. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more seats.
 20. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more radios, televisions, or telephone sets.
 21. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more heating elements for heating water.
 22. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more controllers that monitor or adjust temperature, filter cycles, or speed of jets or current.
 23. The swim spa as recited in claim 1, wherein said swim spa further comprises: one or more interfaces or controls for controlling function of swim spa or hot tub. 